Process for the preparation of siox having a nanoscale filament structure and use thereof as anode material in lithium-ion batteries

ABSTRACT

A process for the preparation of nanofilament particles of SiO x  in which x is between 0.8 and 1.2, the process including: a step of a fusion reaction between silica (SiO 2 ) and silicon (Si), at a temperature of at least about 1410° C., to produce gaseous silicon monoxide (SiO); and a step of condensation of the gaseous SiO to produce the SiO x  nanofilament particles. The process may also include using carbon.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 15/039,615, filed on May 26, 2016, which is a U.S. national stage of International Application No. PCT/CA2014/051141, filed on Nov. 28, 2014, which claims benefit of Canadian application CA 2,835,583 filed on Nov. 28, 2013. The entire contents of each of U.S. application Ser. No. 15/039,615, International Application No. PCT/CA2014/051141, and Canadian Application No. 2,835,583 are hereby incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to anode materials for lithium-ion (Li-ion) batteries. More specifically, the present invention relates to a process for the preparation of SiO_(x) having a nanoscale filament structure and its use as anode material in lithium-ion batteries.

BACKGROUND OF THE INVENTION

Ever since the beginning of work in the field of lithium-ion batteries by the Sony company during the early nineties, this type of batteries has been widely used, leading to a commercial success. Typically, the technology is based on the use of lithium insertion materials as electrode material. Specifically, cobalt oxide is used as cathode material (invented by J. B. Goodenough) and carbon-based materials (coke or graphitized carbon) are used as anode material.

Since then, lithium-ion batteries have progressively replaced Ni—Cd and Ni-MH batteries. Indeed in many electronic applications, lithium-ion batteries perform better than Ni—Cd and Ni-MH batteries. However, because the production cost of lithium-ion batteries is high and because their intrinsic stability is generally compromised under harsh conditions, only small format lithium-ion batteries have been successfully commercialized.

Today the technology is based mostly on the use of anode materials containing graphite. However, it appears that the use of such carbon-based anode imposes a 372 mAh/g limit for the specific energy capacity, with no possibility of further increase.

The use of metallic lithium as anode material has been investigated. Indeed, metallic lithium presents a high energy density and may lead to a high specific energy capacity. However, security issues are associated to the use of metallic lithium. This is due to the growth of dendrites during use. Moreover, a limit on the lifetime after many charge/discharge cycles has been noted. These disadvantages have caused researchers to look for other solutions. For example, the use of silicon (Si), tin (Sn) and their alloys as potential high capacity anode materials has been investigated.

Indeed regarding silicon, this metal allows for a reversible insertion and de-insertion of lithium ions through a reaction between silicon and lithium, 5Si+22Li→Si₅Li₂₂, which corresponds to a theoretical capacity of 4200 mAh/g. This capacity is significantly higher than the capacity for carbon-based materials. However, silicon-based anodes are unstable during cycling due to the high volume expansion of silicon (up to about 320%).

Reducing the particle size of a silicon-based anode material (use of nanoscale particles for example) leads to better cycling performance. Indeed, the use of nanoscale particles allows for the relaxation of internal mechanical constraints associated to the large volume increase [1]. A technique consists of using a material which has a nanoscale filament structure. Indeed, such structure can accommodate the deformations in the radial direction of fibers, thus avoiding pulverization of silicon and loss of electric contacts [1,2].

Another technique for decreasing the volume expansion consists of preparing an intimate mixture of silicon and an inert component that can accommodate the deformation. For example, a fine dispersion of silicon in an inactive matrix which relaxes mechanical constraints and insures electric continuity has been prepared [1,3]. Such compromise may be achieved by using a mixture of Si/SiO₂, at the expense of a partial loss of silicon capacity. In this regard, the use of silicon monoxide (SiO_(x), with x≈1) that has been annealed, allows for a dismutation reaction, 2SiO→SiO₂+Si. The amorphous phase of SiO_(x) outside the reaction equilibrium precipitates silicon in an amorphous SiO₂ matrix, which leads to a material having a theoretical capacity of 1338 mAh/g [4].

The first synthesis of SiO_(x) was performed by Potter in 1907 [5]. Potter noted that at temperatures higher than 1000° C., a rapid reaction between silicon (Si) and silicon oxide (SiO₂) occurs. He further noted that if the reaction occurs under inert atmosphere, the reaction product appears as a brown, light, very fine and voluminous powder.

SiO_(x) is currently commercially available. It is produced at a moderately high temperature (about 1250° C.), under vacuum, according to the following reaction [6]:

An equimolar mixture of SiO₂ powder and Si powder in a tube is heated, under vacuum, until a temperature of 1250° C. is reached. Gaseous SiO formed is directed to an area of the tube that is colder and is condensed. The tube is cooled, re-pressurized, and solid SiO_(x) is recuperated. The solid SiO_(x) is then submitted to a grinding process until the desired granulometry is reached.

The relatively low temperature of the process, about 1250° C., allows for the use of a vacuum tube made in stainless steel (retort furnace). However in return, the partial pressure of gaseous SiO in the tube is maintained at a very low level, which greatly affects the productivity of the process. A micrograph taken by a scanning electron microscope shows a typical aspect of the material (FIG. 1) through its X-ray diffraction analysis. The X-ray diffraction analysis shows the amorphous nature of the material. Indeed, no diffraction pic is observed. This is typical to amorphous SiO that has been cooled rapidly and that has not undergone any dismutation reaction.

It is known that annealing such material at a temperature higher than 900° C., under inert atmosphere, does activate the dismutation reaction of SiO, which leads to the precipitation of a very fine silicon phase in an amorphous silicon matrix [3]:

Indeed, Takami et al. [3] prepared a composite of Si, SiO_(x) and C by dismutation of silicon monoxide and polymerization of furfurylic acid at 1000° C. They reported a reversible capacity of about 700 mAh/g for 200 cycles.

There is still a need for materials having a high energy capacity; advantageously, the capacity is reversible for a high number of cycles. Accordingly, there is also a need for processes for preparing these materials; advantageously, the process is efficient and cost-effective.

A material having a high energy capacity can be a nanometric dispersion of crystalline Si in an amorphous SiO₂ matrix. Lamontagne et al. disclose a process for the preparation of such material. The process uses SiO₂ fume; also the process involves uses of various catalysts [7].

Encouraged by the result obtained by Takami et al. relative to a composite of Si, SiO_(x) and C [3], our research group took up a more close investigation of the use of SiO_(x) as electrode material in Li-ion batteries. We have studied, respectively, the use of SiO_(x) and SiO_(x) mixed with graphite as anode material in lithium-ion batteries [4]. Despite the fact that the coulombic efficiency of the first charge/discharge cycle and the electronic conductivity of SiO_(x) are low, the theoretical specific capacity of SiO_(x) electrodes is good, 1338 mAh/g. We have considered the addition of graphite to SiO_(x).

SUMMARY OF THE INVENTION

The inventors have designed and performed a process for the preparation of a SiO_(x) material having a nanoscale filament structure (nanofilaments, nano-structured particles). The process of the invention comprises a high temperature fusion reaction between SiO₂ and Si which leads to the formation of gaseous SiO, and a condensation reaction of silicon monoxide fume under normal (standard) or reduced pressure. According to a preferred embodiment, the process comprises use of carbon. The material of the invention allows for the fabrication of high performance anodes for lithium-ion batteries.

According to an aspect, the invention relates to:

(1) Process for the preparation of nanofilament particles of SiO_(x) in which x is between 0.8 and 1.2, the process comprising:

-   -   a step consisting of a fusion reaction between silica (SiO₂) and         silicon (Si), at a temperature of at least about 1410° C., to         produce gaseous silicon monoxide (SiO); and     -   a step consisting of condensation of the gaseous SiO to produce         the SiO_(x) nanofilament particles.

(2) Process for the preparation of nanofilament particles of SiO_(x) in which x is between 0.8 and 1.2, the process comprising:

-   -   a step consisting of a fusion reaction between silica (SiO₂),         silicon (Si) and a source of carbon (C), at a temperature of at         least about 1410° C., to produce gaseous silicon monoxide (SiO);         and     -   a step consisting of condensation of the gaseous SiO to produce         the SiO_(x) nanofilament particles.

(3) Process according to item (1) or (2), wherein the SiO₂ is in solid form and the Si is in liquid form.

(4) Process according to item (1) or (2), wherein the fusion step is performed in an induction furnace, an electric arc furnace or a submerged arc furnace.

(5) Process according to item (1) or (2), wherein the condensation step is performed in a low temperature area of a furnace, the gaseous SiO being moved to the low temperature area by a vector gas.

(6) Process according to item (6), wherein the vector gas is an inert gas, preferably Ar, He, N₂; an oxidant gas, preferably air, H₂O, O₂, CO₂; a reduction gas, preferably CO, H₂; a volatile hydrocarbon; or a combination thereof.

(7) Process according to item (1) or (2), wherein the fusion step is performed under vacuum.

(8) Process according to item (1) or (2), wherein the fusion step is performed under inert atmosphere.

(9) Process according to item (8), wherein the inert atmosphere consists of Ar, He or N₂.

(10) Process according to item (1) or (2), wherein the temperature at the fusion step is between about 1450 and about 1700° C., preferably about 1500° C.

(11) Process according to item (2), wherein the source of carbon consists of graphite, charcoal, petroleum coke, charcoal, wood or a combination thereof.

(12) Process for the preparation of nanofilament particles of SiO_(x) in which x is between 0.8 and 1.2, the process comprising the following steps:

-   -   liquid silicon (Si) is introduced in a furnace and the         temperature is brought to at least about 1410° C.;     -   solid silica (SiO₂) is introduced in the furnace while agitating         the mixture and gaseous silicon monoxide (SiO) is produced; and     -   the gaseous SiO is moved to a low temperature area of the         furnace using a vector gas, and condensed to yield the SiO_(x)         nanofilament particles.

(13) Process for the preparation of nanofilament particles of SiO_(x) in which x is between 0.8 and 1.2, the process comprising the following steps:

-   -   solid silica (SiO₂) and a source of carbon are introduced in a         furnace and the temperature is brought to at least about 1410°         C., and metallic silicon (Si) and gaseous silicon monoxide (SiO)         are produced; and     -   the gaseous SiO is moved to a low temperature area of the         furnace using a vector gas, and condensed to yield the SiO_(x)         nanofilament particles.

(14) Process according to item (12), wherein the furnace is an induction furnace, an electric arc furnace or a submerged arc furnace.

(15) Process according to item (12), wherein the furnace is an induction furnace, and the agitation stems from a magnetic field produced by the furnace.

(16) Process according to item (12), wherein the step of introducing the silica in the furnace is accompanied by a purge process during which oxygen present is eliminated.

(17) Process according to item (13), wherein the furnace is a submerged arc furnace.

(18) Process according to item (13), wherein the source of carbon consists of graphite, charcoal, petroleum coke, charcoal, wood or a combination thereof.

(19) Process according to item (12) or (13), wherein the step of producing gaseous SiO is performed under vacuum.

(20) Process according to item (12) or (13), wherein the step of producing gaseous SiO is performed under inert atmosphere.

(21) Process according to item (20), wherein the inert atmosphere consists of Ar, He or N₂.

(22) Process according to item (12) or (13), wherein the temperature is between about 1450 and about 1700° C., preferably about 1500° C.

(23) Process according to item (12) or (13), wherein the vector gas is an inert gas, preferably Ar, He, N₂; an oxidant gas, preferably air, H₂O, O₂, CO₂; a reduction gas, preferably CO, H₂; a volatile hydrocarbon; or a combination thereof.

(24) Process according to any one of items (1) to (23), wherein x is about 1.

(25) Process according to any one of items (1) to (24), wherein SiO₂ is in a form which is quartz, quartzite or a combination thereof.

(26) Process according to any one of items (1) to (25), wherein the SiO_(x) particles are in spherical agglomerates consisting of nanofilaments, each agglomerate having a diameter of about 2 to 10 μm.

(27) Process according to any one of items (1) to (26), wherein the nanofilaments each has a diameter of about 50 nm, and the agglomerates are linked together by spheres each having a diameter of about 100 to 150 nm.

(28) Process according to any one of items (1) to (27), wherein the nanofilament SiO_(x) particles obtained comprise at least one of: amorphous SiO₂, crystalline Si and SiC, preferably SiC is in β form.

(29) Nanofilament particles of SiO_(x) obtained by the process as defined in any one of items (1) to (28).

(30) Material comprising nanofilament particles of SiO_(x) obtained by the process as defined in any one of items (1) to (28).

(31) Use of nanofilament particles of SiO_(x) obtained by the process as defined in any one of items (1) to (28), in the fabrication of an anode material.

(32) Anode comprising nanofilament particles of SiO_(x) obtained by the process as defined in any one of items (1) to (28).

(33) Anode comprising a material as defined in item (30).

(34) Battery comprising an anode as defined in item (32) or (33).

Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a typical aspect of a commercially available SiO material; micrograph taken by an electronic microscope and X-ray diffraction analysis.

FIG. 2 shows the capacity of the anode when commercially available SiO_(x) is used, and when a mixture of SiO_(x) and graphite is used.

FIG. 3 shows an induction furnace equipped with a graphite crucible.

FIG. 4 shows nanofilaments of SiO_(x) obtained by the process of the invention.

FIG. 5 shows the X-ray diffraction analysis of nanofilament particles of SiO_(x) obtained by the process of the invention.

FIG. 6 shows results of cycling formation (electrochemical tests).

FIG. 7 shows results of cycling stability (electrochemical tests).

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The present invention relates to a process for the preparation of a SiO_(x) material, wherein x is between about 0.8 to about 1.2; preferably x is about 1. The SiO_(x) material according to the invention has a nanoscale filament structure (nanofilaments, nano-structured particles).

The process of the invention comprises the synthesis of SiO_(x) particles from condensation of gaseous SiO obtained by a high temperature metallurgic process as outlined below.

A step comprising a fusion reaction between Si(l) and SiO₂(l,s) to produce SiO(g) is performed, under controlled atmosphere. For example, fusion in an induction furnace, a plasma furnace, an electric arc furnace or a submerged arc furnace. The fusion reaction proceeds according to the following reaction:

Thereafter, a gas or mixture of gases is used as vector to move SiO(g) in a cold area for the condensation. Nucleation and growth of solid SiO_(x) nano-structured particles occur during condensation.

According to an aspect, the fusion step may be replaced by a step of carbothermic reduction of SiO₂ as illustrated by the reaction below. Various source of carbon may be used; for example graphite (FIG. 2), coal, petroleum coke, charcoal, wood or a combination thereof. Silica may be, for example, in a form which is quartz, quartzite or a combination thereof.

SiO₂(l,s)+C(s)→SiO(g)+CO(g)

The gas mixture used as vector to move gaseous SiO may comprise inert gases (for example Ar, He, N₂), oxidant gases (for example air, H₂O, O₂, CO₂), reducing gases (for example CO, H₂, volatiles hydrocarbons) or a combination thereof.

EXAMPLES

The following examples are provided solely as illustrative embodiments and should not be interpreted, in any way, as limiting the invention.

Example 1

Metallurgical grade silicon (Si) is melted in an induction furnace equipped with a graphite crucible. The experiment system also comprises a cover for the crucible, a feeding port for feeding argon as vector gas, and a capacitor (FIG. 3).

Liquid silicon is heated to 1500° C. Silica (SiO₂) is added, at the liquid (Si) surface. The crucible cover is then put in place and the process of feeding argon begins. The induction furnace produces a magnetic field which causes the liquid to rotate, leading to SiO₂(s) being dispersed within Si(l). Once oxygen initially present in the system is completely purged, the side reaction producing silica fume stops (2SiO(g)+O₂(g)→2SiO₂(s)) and the reaction producing SiO_(x) particles begins (SiO(g)→SiO(am)). The color of the product changes from white (silica fume, SiO₂) to brown (SiO_(x)).

The material obtained is examined using a scanning electron microscope (SEM) under high magnification. SiO_(x) obtained presents spherical agglomerates having diameters of 2 to 10 μm and a nanoscale fibrous structure. The nanofilaments have a diameter of about 50 nm and are joined together by spheres having diameters of about 100 to 150 nm (FIG. 4).

According to the X-ray diffraction analysis (FIG. 5), the particles comprise amorphous silica (SiO₂), crystalline silicon (Si) and silicon carbide (SiC) (β form). SiO_(x) has thus undergone a dismutation reaction leading to a nanometric dispersion of crystalline Si in an amorphous SiO₂ matrix.

The total amount of oxygen, measured by LECO, shows a similar level of oxygen for commercially available SiO_(x) and for SiO_(x) obtained in Example 1.

Example 2

Metallic silicon is prepared, using a submerged arc furnace, by carbothermic reduction of quartz (SiO₂) with reducing materials such as mineral coal, charcoal or coke petroleum. During the reaction, about 80% of silicon is reduced according to the following global reaction:

An intermediate reaction occurs, which is the production of gaseous SiO in the hottest area of the furnace (the arc), according to the following reaction:

SiO₂+C→SiO(g)+CO(g)

In order to allow for retrieval of a sample of SiO_(x), a modification was made to the arc furnace, which consists of creating a longitudinal opening in one of the graphite electrodes. Gaseous SiO leaving the reaction area was sucked through the opening. Gaseous SiO flowing through the electrode condenses once it reaches a colder area, in absence of oxygen, according to the following reaction:

SiO(g)→SiO(am)→Si(cr)+SiO₂(am)

SiO_(x) obtained is fibrous, as in the first synthesis, and presents the same diffractogram as the one obtained for the sample in Example 1: an amount of SiO undergoes dismutation leading to metallic silicon and amorphous quartz; moreover, the carbon-rich atmosphere leads to the production of traces of silicon carbide (SiC).

Example 3

A composite electrode is fabricated by mixing the active material (SiO_(x)) with 25% wt of carbon black (Denka black) and 25% wt of binder (sodium alginate, Aldrich) in a solvent consisting of deionized water to obtain a homogenous dispersion, which is then deposited on a current collector made of copper. The electrode is dried for 20 hours under vacuum at 110° C. A button cell of CR2032 format is assembled in a glovebox full of helium. The electrolyte used is LiPF₆ (1M) in a 3:7 (v/v) mixture of ethylene carbonate (EC) and diethyl carbonate (DEC) with 2% wt vinylene carbonate (VC) (Ube). The counter electrode is a thin film of lithium. The electrochemical tests on the battery are performed by discharge/charge cycling in galvanostatic mode within a potential of 0.005 to 2.5 V at a C/24 speed (FIG. 6). Once the reversible capacity is measured, cycling of the battery is performed in order to measure its stability at a C/6 speed (FIG. 7).

Although the present invention is described by way of specific embodiments thereof, it is to be understood that various variations and modifications may be linked to these embodiments. The present inventions covers such modifications, uses or adaptations of the invention in general, the principles of the invention including any variation which will become known or conventional in the field of the invention, and which may apply to essential elements indicated above in accordance with the scope of the claims.

The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

REFERENCES

-   [1] Uday Kasavajjula, Chunsheng Wang, A. John Appleby; Nano- and     bulk-silicon-based insertion anodes for lithium-ion secondary cells,     Journal of Power Sources 163 (2007) 1003-1039. -   [2] Candace K. Chan, Hailin Peng, Gao Liu, Kevin Mcllwrath, Xiao     Feng Zhang, Robert A. Huggins and Yi Cui; High-performance lithium     battery anodes using silicon nanowires, Nature Nanotechnology, vol.     3, January 2008, pp. 31-35. -   [3] T. Morita, N. Takami, Nano Si Cluster-SiO—C Composite Material     as High-Capacity Anode Material for Rechargeable Lithium, Journal of     the Electrochemical Society, 153 (2) A425-A430 (2006). -   [4] A. Guerfi, P. Charest, M. Dontigny, J. Trottier, M. Lagacé, P.     Hovington, A. Vijh, K. Zaghib; SiO_(x)-graphite as negative for high     energy Li-ion batteries, Journal of Power Sources, Volume 196, Issue     13, 1 Jul. 2011, pages 5667-5673. -   [5] U.S. Pat. No. 1,104,384. -   [6] H.-D. Klein, F. König, Production, Properties and Application of     Silicon Monoxide, in: R. Corriu, P. Jutzi (Eds.), Tailor-made     silicon-oxygen compounds—from molecules to materials, Vieweg,     Braunschweig, Weiesbaden, 1996, pp. 141-145. -   [7] P. Lamontagne, G. Soucy, J. Veilleux, F. Quesnel, P.     Hovington, W. Zhu and K. Zaghib; Synthesis of silicon nanowires from     carbothermic reduction of silica fume in RF thermal plasma; Phys.     Status Solidi A, 1-7 (2014). 

1-34. (canceled)
 35. A process for the preparation of nanofilament particles of SiO_(x) in which x is between 0.8 and 1.2, the process comprising: a step comprising a fusion reaction between silica (SiO₂) and liquid silicon (Si), at a temperature of at least about 1410° C., to produce gaseous silicon monoxide (SiO); and a step comprising condensation of the gaseous SiO to produce the SiO_(x) nanofilament particles, wherein the condensation step is performed in a low temperature area of a furnace, the gaseous SiO being moved to the low temperature area by a vector gas.
 36. The process according to claim 35, wherein the SiO₂ is in solid form.
 37. The process according to claim 35, wherein the fusion step is performed in an induction furnace, an electric arc furnace or a submerged arc furnace.
 38. The process according to claim 35, wherein the vector gas is selected from the group consisting of inert gas, oxidant gas, reduction gas, volatile hydrocarbon and combinations thereof.
 39. The process according to claim 35, wherein the fusion step is performed under vacuum.
 40. The process according to claim 35, wherein the fusion step is performed under inert atmosphere which is of Ar, He or N₂.
 41. The process according to claim 35, wherein the temperature at the fusion step is between about 1450 and about 1700° C.
 42. The process according to claim 35, wherein the furnace is an induction furnace, and the agitation stems from a magnetic field produced by the furnace.
 43. The process according to claim 35, wherein x is about
 1. 44. The process according to claim 35, wherein the SiO₂ is in a form which is quartz, quartzite or a combination thereof.
 45. The process according to claim 35, wherein the SiO_(x) particles are in spherical agglomerates consisting of nanofilaments, each agglomerate having a diameter of about 2 to 10 μm.
 46. The process according to claim 45, wherein the nanofilaments each have a diameter of about 50 nm, and the spherical agglomerates are linked together by spheres each having a diameter of about 100 to 150 nm.
 47. The process according to claim 35, wherein the nanofilament SiO_(x) particles obtained comprise at least one of: amorphous SiO₂, crystalline Si and SiC.
 48. Nanofilament particles of SiO_(x) obtained by the process as defined in claim
 35. 49. A method comprising fabricating an anode with nanofilament particles of SiO_(x) obtained by the process as defined in claim
 35. 50. A material comprising nanofilament particles of SiO_(x) in which x is between 0.8 and 1.2 obtained by a process comprising: a step comprising a fusion reaction between silica (SiO₂), liquid silicon (Si), and, at a temperature of at least about 1410° C., to produce gaseous silicon monoxide (SiO); and a step comprising condensation of the gaseous SiO to produce the SiO_(x) nanofilament particles, wherein the condensation step is performed in a low temperature area of a furnace, the gaseous SiO being moved to the low temperature area by a vector gas.
 51. An anode comprising the material as defined in claim
 50. 52. A battery comprising the anode as defined in claim
 51. 